Fabrication of Biodegradable Polyurethane Foam Scaffolds with Customized Shapes and Controlled Mechanical Properties by Gas Foaming Technique

Poly(ε-caprolactone) (PCL)-based polyurethane (PU) foam scaffolds with different mechanical properties are fabricated using a gas foaming technique to use as porous substitutes for ear or bone with cartilage. PCL diol or triol is used as a polyol in PU foam for biocompatibility and biodegradation, with an aqueous gelatin solution as a blowing agent. The highly porous inner and outer structures of the scaffolds are developed by employing a silicone surfactant and sulfuric acid, respectively. The PU scaffolds prepared by PCL diol show ductile and flexible properties, whereas the PU scaffolds prepared by PCL triol exhibit high compression strength. In vitro test reveals the low toxicity of the PU scaffolds and the high ALP activity of MC3T3-E1 cells in the PU scaffold prepared by PCL triol. By taking advantage of the difference in mechanical properties, customized PU scaffolds with ear or bone shapes are fabricated using a silicone mold. The PU scaffolds with two compartments of PCL diol and triol (corresponding to cartilage and bone, respectively) are fabricated as a substitute for bone with cartilage. It is believed that the PU scaffolds with highly porous structure and controlled mechanical properties have wide potential application for tissue engineering.